India’s tyre recycling sector, long plagued by fragmented operations and lax compliance, is undergoing a critical overhaul. With Gujarat’s recent approval for continuous pyrolysis plants, the industry is moving decisively towards cleaner, scalable and regulation-driven solutions. This shift signals more than a technological upgrade and it’s a rebuke of outdated batch systems and a call for formalisation, traceability and environmental accountability. As global demand for sustainable materials rises, India’s pivot positions it as a potential leader in circular economy practices. In conversation with TRRAI President Chetan Joshi, we explore how this development could redefine the future of tyre waste management at home and abroad.

India’s tyre recycling sector is on the cusp of a transformational shift with the Gujarat Pollution Control Board (GPCB) approving the establishment of continuous pyrolysis plants in the state. The move marks a significant departure from traditional batch-based tyre processing systems, promising to boost efficiency, environmental compliance and resource recovery at an industrial scale.

“This shift is nothing short of revolutionary,” said President of the Tyre and Rubber Recyclers Association of India (TRRAI) Chetan Joshi. “We’re moving from outdated, fragmented batch operations to streamlined, automated continuous pyrolysis systems. This is going to uplift the entire industry, from cleaner emissions to higher resource recovery, better traceability and serious investor interest. It sets a new national standard and will accelerate formalisation, industrial-scale operations and a far more sustainable approach across India.”

The approval has been met with optimism by recyclers and environmental advocates alike as it signifies a structural change in how end-of-life tyres will be handled in India, which is home to more than 1.8 million tonnes of tyre waste annually.

The Gujarat model mandates stringent adherence to environmental standards, particularly concerning air quality and emissions. Continuous pyrolysis plants approved under the new framework are required to incorporate top-tier pollution control mechanisms.

“We see compliance not as an obligation but as a core design principle. Our plants are being built with advanced air pollution control devices (APCDs), real-time emissions monitoring and automation that ensures consistent performance. We’re aligning with both GPCB and CPCB regulations through pro-active design, third-party audits and integrating global best practices. It’s not just about meeting today’s standards but staying ahead of tomorrow’s,” said Joshi.

The approach reflects a broader shift in the recycling sector, where regulatory compliance is no longer viewed as a hurdle but as a strategic advantage and market differentiator.

Industrial scale

Under the new directive, each continuous pyrolysis facility must operate at a minimum capacity of 60 tonnes per day (TPD). This scale reflects the government’s push to industrialise tyre recycling and eliminate inefficient, informal practices.

“Scaling to 60 TPD is a serious industrial commitment and it means heavy investment in automation, utilities, safety systems and logistics. But it’s also the only way forward. India generates over 1.8 million tonnes of end-of-life tyres annually. This scale allows us to handle the problem responsibly while creating traceable and economically viable recycling ecosystems,” Joshi said.

With India’s growing automotive base, the urgency to develop sustainable, high-capacity recycling infrastructure has never been higher.

One of the key advantages of continuous pyrolysis lies in its outputs that include valuable petrochemical byproducts like pyrolysis oil, sustainable fuels and recovered carbon black (rCB). These materials are increasingly in demand across a range of industries, from rubber manufacturing to renewable energy.

“These by-products are entering a new phase of global relevance. Recovered carbon black is being adopted in rubber, plastics and even pigments. Pyro oil, when upgraded, is a viable alternative fuel. We’re actively engaging with global buyers and certifiers to standardise and integrate these outputs into international supply chains. The world is ready for sustainable alternatives and it’s up to us to deliver with consistency and quality,” averred Joshi.

India’s entry into this global supply chain positions it not just as a recycler of waste but as a producer of sustainable industrial materials.

Circular economy

TRRAI views this milestone as more than an environmental success. It’s a step towards realising India’s vision of a circular economy, where tyre waste is fully reintegrated into the production cycle.

“We aim to be more than recyclers. We want to be circular economy enablers. That means building systems where tyre waste is traceable from collection to output, where value is recovered and re-injected into the economy. We’re developing collection infrastructure, digital traceability and offtake agreements with industries globally. This is not just about waste; it’s about resource optimisation and environmental stewardship,” Joshi explained.

Such a shift could significantly reduce the country’s carbon footprint while fostering job creation and industrial growth.

Despite the enthusiasm, industry leaders acknowledge that challenges remain, particularly in terms of adoption among legacy operators and infrastructure gaps.

“The biggest challenge is inertia as many operators are still working in the unorganised sector with outdated setups. Then there’s infrastructure as a hurdle as tyre collection networks are underdeveloped in many parts of India. To overcome this, we’re advocating policy changes, investing in reverse logistics and training the workforce. Regulatory clarity and enforcement will be key and we’re working closely with industry associations and government bodies to drive this,” said Joshi.

Stakeholders believe that education, investment and enforcement will be pivotal to ensuring widespread transition to continuous pyrolysis systems.

Global trends

Globally, countries like those in Europe and North America have already adopted advanced tyre recycling technologies. But Joshi believes India has a unique opportunity to leapfrog older systems and build world-class facilities from scratch.

“Europe and North America have a head start, especially in policy frameworks and end-use applications. But India’s opportunity lies in scale and adaptability. We can leapfrog legacy systems and build efficient, tech-driven plants from the ground up. If we get the ecosystem right – collection, compliance and capital – we can set new benchmarks, not just catch up. India could become a global hub for tyre recycling technology,” he said.

The industry’s fast pace of development combined with India’s manufacturing and engineering capabilities could make the country a case study in sustainable industrial transformation.

Innovations in emission reduction

In line with global best practices, TRRAI and its partners are integrating innovations to ensure safety and minimal environmental impact.

“We’re integrating closed-loop systems, AI-driven control logic and multi-stage gas cleaning technology. Real-time emissions data will be available both internally and to regulators. Safety protocols are built into every operational layer, from material feeding to shutdown procedures. We’ve also prioritised workforce training and regular third-party safety audits. The goal is to operate with zero compromise on health or the environment,” Joshi explained.

Such innovations are crucial not only to maintaining regulatory compliance but also to building public and investor confidence.

The entry of advanced technologies is expected to catalyse foreign investment and technical collaboration.

“Our approach is partnership-driven. We’re already working with European and Australian technology providers and are in discussions with institutional investors. We see India as a platform for co-creation, where global IP meets local scale and agility. Through industry associations like TRRAI, we’re building collaborative networks to ensure knowledge sharing, investment facilitation and joint innovation,” Joshi noted.

This strategy could help India become a global innovation hub for recycling technologies applicable across other emerging markets.

The vision

Looking to the long term, the industry’s goals extend far beyond domestic waste management. TRRAI envisions exporting its model to developing nations facing similar challenges.

“Our vision is bold but simple. It is to create a fully circular, scalable and replicable tyre recycling ecosystem. India should not only solve its own tyre waste crisis but become a global model for how emerging markets can tackle resource recovery. We see this model being exported to Southeast Asia, Africa and Latin America. With continuous pyrolysis, India can move from reactive recycling to proactive resource management on a global stage,” Joshi concluded.

As Gujarat lights the way with its approval of continuous pyrolysis plants, India’s tyre recycling sector is poised to become a beacon of innovation and sustainability – one that could shape the future of global recycling practices. n

Comments (0)

ADD COMMENT

Link Copied!

Recovered carbon black is edging closer to mainstream adoption as ASTM International committee D36 on Recovered Carbon Black develops a new ash content standard, D8621. The test promises to slash analysis times from 18 hours to just a few, a change that could reshape productivity and quality control for tyre makers and rCB producers. Yet the push for faster monitoring also exposes a bigger challenge, as standardisation alone will not guarantee industry-wide adoption. With high capital investment, scaling hurdles and safety considerations, the new method sits at the intersection of technical progress, economic pressure and the tyre industry’s sustainability ambitions.

The ASTM International’s recovered carbon black (rCB) D36 committee developed and published a new standard called D8621, which will improve productivity of tyre makers and also enhance production process monitoring abilities.

Speaking exclusively to Tyre Trends, ASTM D36 Chair and Director of rCB at Circtec, Pieter Ter Haar, said, “The D1506 method was developed for regular carbon black, which typically has an ash content of <1 percent. rCB typically has an ash content between 15 and 30 percent.”

The new standard promises to cut testing times from 18 hours to just a few. Commenting on this, he said, “This rCB-specific test method requires less material, and by operating the furnace at a higher temperature, the rate-of-reaction is optimised for rCB, resulting in the significant reduction in time. Since ash content is one of the important product specifications, reducing the time to obtain results is of great help in quality control of the production process of rCB.”

“The main benefit is the significant reduced time required to obtain ash content information of the rCB sample from a tailor-made test method. The future bias and precision study will have to show if the method also has an improved standard deviation,” he added.

CONSENSUS BUILDING

The method’s creation reflects the convergence of some of the industry’s biggest players. “This standard was created by the globally leading rCB, carbon black and tyre manufacturers who come together in the committee. We will actively try to promote the use of this method going forward both for producers and users,” said Ter Haar.

He argued that the proposed standard could reshape the economics of rCB production, particularly in terms of reducing waste or lowering costs as more process control will typically result in less waste and a quicker ability to adjust feedstock ratio’s when changes need to be made.

“This new method will also help tyre manufacturers analyse rCB faster and this will, however, not likely play a role in competitiveness compared to virgin carbon black,” he stated.

According to Ter Haar, the temperature of the muffle furnace has increased from 550 degrees Celsius to 700 degrees Celsius, which is an important consideration for the manufacturer using this method when it comes to safe execution of this method. Besides, he wasn’t aware of any other potential risks or limitations that need to be considered.

Alluding to how critical is standardisation in gaining wider adoption of rCB within tyre production supply chains from Circtec’s perspective, Ter Haar explained, “Standardisation will not be the silver bullet for better understanding of rCB or overcoming the initial adoption phase of rCB in rubber compounds. However, when it comes to consistent supply of rCB, relevant rCB-specific specifications are crucial.”

SUSTAINABILITY PUSH

ASTM Standard D8621 fits neatly into the tyre industry’s strategic pivot towards greener materials. According to Ter Haar, the new standard is part of the wider industry development of the rCB producers and adaptation to the needs and requirements of the tyre industry for adoption of new raw materials for the construction of tyres.

He pointed to high levels of capital deployment, the emergence of reputable producers across global regions and platforms like ASTM as proof that rCB is on track to become a cornerstone of tyre sustainability.

“There are very few sustainable raw material options available for the tyre industry that seem to be developing into mature industries,” the spokesperson noted, stressing that rCB is now positioned as a key strategic material for fulfilling long-term sustainability and circularity objectives.

Circtec itself is pushing hard to lead the charge. Later this year, the company will open its third European factory in the Netherlands. The facility, built to a scale comparable with regular carbon black plants, is expected to convert around six percent of all waste tyres in Europe into sustainable products once it reaches full capacity.

“We will continue to focus on the global expansion of Circtec and the development of the sector when it comes to regulatory compliance, technical knowledge and producing high-quality rCB at large industrial scale,” he said.

INDUSTRY RECEPTION

The new standard has already won the backing of the tyre industry. “The tyre industry was an active participant in the development and approval process of this new standard,” Ter Haar emphasised.

The benefit is straightforward, which is more precise quality control. “Any time one of the raw material suppliers can improve their quality control, this is welcomed. The main objective of any new standard is that the test method is technically relevant and improves the ability to test rCB’s characteristics that actually correlate to in-rubber performance,” he explained.

For producers, the efficiency gains are significant. At Circtec’s Netherlands plant, for instance, output is expected to reach 10 tonnes of rCB per hour. At these production rates, quick quality control test methods are crucial.

While faster process monitoring will primarily benefit producers with scaled up production capacity, Ter Haar noted that the standard is not necessarily designed to spark innovation in rCB applications beyond tyres such as plastics or coatings.

Crucially, adopting the new standard won’t require expensive technical upgrades. “The benefit of this method and aim during the development is that for most producers or end-users, there would not be a need for any new investments in equipment. This method is based on the use of an affordable ashing muffle furnace with the ability to heat to 700 degrees Celsius,” he said.

ADOPTION DYNAMICS

ASTM standards remain voluntary, but Ter Haar expects uptake to be swift given the operational advantages. “This new standard is a tool to improve the speed of quality control. It is up to the individual parties to adopt this or any other ASTM method. Due to the clear advantages of this method, I would expect both producers and users to welcome using this test method moving forward,” Ter Haar said.

The development also represents a milestone in a broader strategic roadmap. The ASTM committee D36 on Recovered Carbon Black, formed eight years ago, initially issued guidance on which carbon black test methods could or should not be used.

“At the moment, most of the key product performance characteristics of rCB can be determined,” he observed, suggesting that D8621 could be a stepping stone towards a broader suite of rCB-specific standards on par with virgin carbon black testing.

As rCB moves into the mainstream, the combination of industrial-scale production, regulatory support and technical validation is setting the stage for what could become one of the tyre industry’s most significant sustainability transformations in decades.

Comments (0)

ADD COMMENT

Link Copied!

Members of the Global Platform for Sustainable Natural Rubber gathered for the organisation’s seventh General Assembly, marking what it described as a pivotal year for accountability and member-led sustainability across the natural rubber value chain.

A key development in 2025 was the launch of GPSNR’s risk-based Assurance System, which sets sustainability expectations, introduces independent verification and aims to drive continuous improvement beyond regulatory compliance. The system was developed collaboratively over several years and is intended to provide a globally applicable framework for sustainability in the sector.

At the assembly, end-user companies reaffirmed their support for the Assurance System and agreed on a structured pathway towards full implementation within their category.

“This year marks a turning point for GPSNR,” said Stefano Savi, chief executive of GPSNR. “The Assurance System gives our members a shared and trusted foundation for demonstrating progress across the value chain.”

Members also reflected on the first year of the Shared Investment Mechanism, a model that allows manufacturers to share the costs of large-scale capacity-building projects. The initiative is intended to deliver long-term benefits for upstream participants, particularly smallholder producers.

“Sustainability cannot be achieved by one part of the value chain alone,” Savi said. “By investing together, our members are enabling more inclusive and impactful outcomes worldwide.”

Looking ahead to 2026, GPSNR said it would focus on supporting the implementation of the Assurance System through data collection, member learning programmes, and stakeholder dialogue, to ensure the framework reflects operational realities and different business models.

The assembly concluded with members reiterating their commitment to building more equitable, resilient and sustainable natural rubber supply chains.

Comments (0)

ADD COMMENT

Link Copied!

The Tire Recycling Foundation has opened nominations for its first Circle of Change Awards, aimed at recognising organisations, teams and individuals advancing innovation and sustainability across the tyre recycling sector.

Nominations opened on 15 December and will be accepted until 8 February  2026. The awards will honour contributions spanning tyre recycling technologies, end-use market development and leadership in circular economy practices.

“The Circle of Change Awards will serve as a powerful way to recognise national visionaries and changemakers who have shaped the trajectory of the full tyre recycling value chain over the past two decades,” said Anne Forristall Luke, president of the Tire Recycling Foundation board. “We are thrilled to recognise trailblazers making a lasting impact on end-of-life tyre (ELT) recycling and the circular economy.”

Four award categories will be presented at the 10th Tire Recycling Conference, scheduled to take place in Denver, Colorado.

“By spotlighting the collective progress being made in tyre recycling, the Foundation hopes these inaugural awards will inspire and fuel accelerating momentum in exciting new markets for recycled tyres,” said Stephanie Mull, executive director of the Tire Recycling Foundation.

The Innovation in End-Use Technology Award will recognise technologies, products or processes that use recycled tyre rubber in new ways, with a focus on technological advancement, commercialisation and sustainability impact.

The Circular Economy Trailblazer Recognition, State Leadership in Tire Market Innovation category will honour state agencies or statewide programmes that demonstrate leadership and measurable impact in advancing tyre recycling within a circular economy framework.

The Market Development Excellence Award will recognise efforts to expand end-use markets for tyre-derived materials through education, policy, marketing or advocacy, with an emphasis on measurable market growth and long-term strategy.

The Value Chain Collaboration Award will acknowledge partnerships across the tyre recycling value chain that deliver measurable improvements in efficiency, economics or environmental performance.

The foundation said organisations and individuals that have made significant contributions to tyre recycling or developed innovative solutions for tyre-derived materials are encouraged to apply. Award recipients will be allowed to showcase their achievements and inspire further progress across the sector.

Comments (0)

ADD COMMENT

Link Copied!

The German Rubber Industry Association (wdk) has called for enhanced policies to unlock the full potential of tyre recycling in Germany. While acknowledging the existing successes of the circular economy in this sector, Stephan Rau, Technical Director of wdk, emphasised that significant untapped opportunities remain. Last year alone, Germany generated 533,000 tonnes of used tyres, with nearly 70 percent kept in circulation through reuse, retreading and recycling. The wdk advocates for a stronger framework to improve these material flows and boost the market for recycled materials.

A central pillar of the wdk’s position is the demand for a modern, science-based evaluation of recycled rubber products. Over 200,000 tonnes of used tyres are processed annually into granules and rubber flour, vital secondary raw materials for sustainable manufacturing. However, Rau argues that their broader market success is hindered by outdated assessment methods. The association urgently recommends a risk-based approach that evaluates chemical ingredients based on their actual bioavailability and migration, rather than their mere presence. This perspective, now supported by the German Federal Institute for Risk Assessment (BfR), necessitates establishing binding limit values determined through migration analysis to ensure both safety and commercial viability.

Furthermore, the wdk highlights a critical gap in the complete monitoring of tyre material flows. A notable proportion of used tyres exit Germany and Europe for processing, depriving domestic recyclers of valuable secondary raw materials. To address this leakage and strengthen the circular economy, Rau stresses the need for comprehensive tracking of all end-of-life tyres. The association’s commitment is reflected in its patronage of the Alliance for Future Tyres (AZuR), a European network of nearly 100 partners from industry, trade and science dedicated to advancing a sustainable tyre circular economy across all segments.

Comments (0)

ADD COMMENT

Link Copied!